Bundle wrapping apparatus and associated methods

ABSTRACT

Various embodiments of the present invention provide devices and processes for packaging elongate items in shippable bundles using a corrugated slip sheet and wrapping material. The elongate items may then be stacked within a frame. The frame with the stacked elongate items may then be wrapped with a wrapping material. Next, the stack of elongate items with the wrapping material may be removed from the frame as a single unitized bundle for storage and subsequent shipment.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 61/317,542, filed Mar. 25, 2010, which is incorporated herein by reference in its entirety.

FIELD OF THE INVENTION

Embodiments of the present invention generally relate to devices and processes for packaging elongate items using slip sheets and wrapping materials.

BACKGROUND OF THE INVENTION

A challenge facing area rug manufacturers is how to efficiently store and transport rugs of varying sizes to their customers. Typically, rug manufacturers roll the rugs into a substantially cylindrical form and place each individual rug into a plastic bag to protect it from contamination. These rolled rugs are then stacked in a warehouse for storage and eventual shipment to a retailer.

Once an order has been received, the associated rolled rugs are pulled from the warehouse and placed into a box disposed on a pallet. A problem sometimes encountered with this packaging method is that the weight of the rolled rugs causes the box to split requiring restacking into another box or in some cases replacement of damaged rugs. A second problem is that the retailer receiving the rugs must dispose of both the pallet and the box once the rugs are placed into inventory.

Thus, a need exists for improved packaging techniques for elongate items such as rolled rugs.

BRIEF SUMMARY OF THE INVENTION

In general, various embodiments of the present invention provide devices and processes for bundling elongate items using slip sheets and wrapping material.

In one aspect of the invention, a bundle of elongate items is provided. The bundle includes a slip sheet having a planar base portion and at least one flap extending from the base portion. A plurality of elongate items are disposed in a plurality of rows atop the slip sheet, where a first row is disposed adjacent to the base portion with a longitudinal axis of the elongate items substantially parallel with the plane formed by the base portion. A wrapping material is disposed around the plurality of rows, where the wrapping material engages both ends of the elongate items and at least a portion of the slip sheet.

In another aspect of the invention, a bundling system for packaging a plurality of elongate items is provided. The bundling system includes a stacking frame configured to align the elongate items. The stacking frame includes a substantially planar platform and a plurality of posts attached to the platform, where the posts position the platform at a position spaced apart from a supporting surface. A plurality of support blocks are attached to the frame. The bundling system also includes an undocking station comprising a plurality of rails configured to slideably engage the support blocks to restrict movement of the stacking frame in a direction substantially perpendicular to the platform.

In a further aspect of the invention, a method of bundling a plurality of elongate items is provided. The method includes the steps of: stacking a plurality of elongate items into a plurality of rows atop a slip sheet; and applying wrapping material around the stack of elongate items where the wrapping material engages the ends of the plurality of elongate items and at least a portion of the slip sheet.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:

FIG. 1 is a schematic diagram illustrating a bundle of elongate items in accordance with an embodiment of the present invention.

FIG. 2 is schematic diagram of a stacking frame in accordance with an embodiment of the present invention.

FIG. 3 is a schematic diagram of the stacking frame in FIG. 2 with a slip sheet and a rug roll placed thereon.

FIG. 4 is a schematic diagram of a wrapping station in accordance to an embodiment of the present invention.

FIG. 5 is a schematic diagram of an undocking station in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Various embodiments of the present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the inventions are shown. Indeed, these inventions may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. The term “or” is used herein in both the alternative and conjunctive sense, unless otherwise indicated. The terms “illustrative” and “exemplary” are used to be examples with no indication of quality level. Like numbers refer to like elements throughout.

Generally described, various embodiments of the present invention provide devices and processes for packaging elongate items in shippable bundles using a slip sheet and wrapping material. The elongate items may be, for example, area rugs (e.g., 3 ft.×5 ft., 5ft.×8 ft., 8 ft.×10 ft., etc.) that are individually rolled and may be placed into individual plastic bags. In various embodiments, the devices used to create the stack of elongate items include a stacking frame 20 and an undocking station 40. The elongate items are initially stacked in rows atop a slip sheet disposed within the stacking frame 20. After the desired number of elongate items is stacked within the stacking frame 20, the stacking frame 20 and the elongate items are wrapped together with a wrapping material. The stacking frame 20 is then engaged by the undocking station 40 and the elongate items with the wrapping material are lifted from the stacking frame 20. The result is a unitized bundle of elongate items that are held together with wrapping material. This provides a secure stack of elongate items that can be shipped or placed in storage.

FIG. 1 illustrates an exemplary unitized bundle 10 according to an embodiment of the present invention. In this embodiment, the unitized bundle 10 includes a plurality of rolled rugs 5 stacked on a slip sheet 12. One or more layers of wrapping material surround the stack of rolled rugs 5 and engage at least a portion of the slip sheet 12. This wrapping material holds the stack together. In one particular embodiment, 70 5 ft by 8 ft rolled rugs are stacked on a slip sheet and held together with an elastic film. In other embodiments, more or less rolled rugs may be provided in a single stack.

Stacking Frame 20

FIG. 2 illustrates a stacking frame 20 that may be used to stack the elongate items prior to application of the wrapping material. The stacking frame 20 includes a platform 24 with four posts 22A-D attached thereto. The stacking frame 20 is sized such that the ends of the elongate rolled rugs to be stacked thereon will extend beyond the frame posts 22A-D. This allows for additional engagement between the wrapping material and the rolled rugs 5 when the wrapping material is applied. In one embodiment, the rolled rugs overhang each side by approximately 4 to 5 inches. In other embodiments, the rolled rugs may overhang the sides of the stacking frame 20 by more or less 5 inches.

In various embodiments, the posts 22A-D position the platform 24 substantially parallel to and spaced apart from a supporting surface such as a floor. This space may allow the stacking frame 20 to be easily moved using a pallet jack or fork lift. In the illustrated embodiment, the posts 22A-D are spaced apart with two posts (e.g., 22A-B) attached along one edge of the platform 24 and two other posts (e.g., 22C-D) attached along the opposite edge of the platform 24. In other embodiments, more or less posts may be used and the posts may be attached to different sides of the platform 24 as desired.

In the illustrated embodiment, a bar 28 is positioned proximate an edge of the platform and extends between posts 22A, D. In use, this bar 28 cooperates with the platform 24 to position the slip sheet 12 and rolled rugs 5 placed thereon on an incline relative to the supporting surface. As will be discussed in greater detail below, the inclined orientation of the stack of rolled rugs 5 can facilitate application of the wrapping material 34. Other embodiments, however, may not include the bar 28 and instead, the posts 22A-D position the platform 24 with an incline relative to the support surface. In further embodiments, the stacking frame 20 may include a platform 24 oriented substantially parallel with the supporting surface without a bar 28. It should also be understood that some embodiments may include multiple bars supporting the slip sheet 12 and orienting the slip sheet 12 and rolled rugs 5 either inclined or parallel with the supporting surface.

In the illustrated embodiment, support blocks 26 are disposed on the opposite side of the posts 22A-D from the platform 24 proximate the ends of the posts 22A-D that engage the supporting surface. As will be discussed in greater detail below, these support blocks are configured to engage the undocking station 40. It should be understood that the support blocks may be positioned on other surfaces of the stacking frame 20 with an associated change to the undocking station to allow engagement thereof.

FIG. 3 illustrates a stacking frame 20 with a slip sheet 12 and a rug roll 5 positioned thereon. In various embodiments, the slip sheet 12 may be constructed of cardboard, plastic or metal. The slip sheet 12 is positioned atop the platform 24. The slip sheet 12, in various embodiments, has a substantially planar rectangular bottom portion 15 with three edges folded upward to form two side walls 16, 17 and a back wall 18. In this embodiment, both of the side walls 16,17 are attached to the back wall 18 using tape, adhesive, staples, tab and slot engagement between adjacent walls, or other attachment techniques. In various embodiments, a flap 14 extends from the fourth side. In various embodiments, the demarcation between the flap 14 and the bottom portion 15 may be a scored line or other demarcation technique. Some embodiments may include the flap folded upwardly and attached to the adjacent side walls to form a box. In some embodiments, the slip sheet 12 may not include one or more of the side walls, back wall, or flap.

In the illustrated embodiment, a rolled rug 5 is positioned atop the slip sheet 12 with one end of the elongate rolled rug disposed proximate to the back wall 18 of the slip sheet and the opposite end proximate the flap 14. In this orientation, the longitudinal axis of the elongate rug roll 5 is inclined relative to the support surface and substantially parallel with the inclined plane created by the bottom portion 15 of the slip sheet 12. Subsequent rolled rugs may be disposed substantially parallel to the illustrated rug roll 5 to form a first row of rolled rugs between the posts 22A,B and posts 22C, D of the stacking frame 20. Further rolled rugs may be added to the stack in additional rows until the desired number of rolled rugs is added to the stack.

The inclined orientation of the rug roll stack can facilitate placement of the wrapping material 34. More specifically, this inclined orientation can facilitate engagement by the wrapping material 34 of a portion of the underside of the slip sheet 12 proximate the raised side (e.g., back wall 18) and also discourage engagement of the flap 14 of the slip sheet 12 on the opposite side.

As illustrated, the posts 22A-D provide lateral support for rolled rugs 5 being stacked atop the slip sheet 12. Once the desired number of rolled rugs are stacked, the stacking frame 20, slip sheet 12, and rolled rugs 5 positioned thereon may be moved to the wrapping station 30.

Wrapping Station 30

FIG. 4 illustrates a wrapping station 30 in accordance with an embodiment of the present invention. In the illustrated embodiment, the stacking frame 20, with the rolled rugs 5 and slip sheet 12 disposed thereon, is placed on a turntable 35. A wrapping material dispenser (not shown) is positioned proximate the turntable 35 such that the wrapping material is applied about the rolled rugs 5 and engages the ends of the rolled rugs 5. In various embodiments, the wrapping material may applied at an angle relative to the longitudinal axis of the rolled rugs. The angle is due in part to the incline created by the engagement of the slip sheet 12 and the rolled rugs 5 with the bar 28 and the platform 24. In embodiments where the rolled rugs 5 are substantially parallel with the support surface, the wrapping material 34 may be applied substantially perpendicular to the longitudinal axis of the rolled rugs 5.

The wrapping material dispenser may comprise a frame that disposes a roll of wrapping material proximate the turntable 35. The dispenser may orient the roll of wrapping material perpendicular to the axis of rotation for the turntable 35 or inclined relative to the turntable 35 axis of rotation as desired.

Once the wrapping process is initiated, the turntable 35 rotates and wrapping material 34 is applied from a wrapping material dispenser (not shown), which may remain substantially stationary as the turntable 35 rotates. In other embodiments, the wrapping material dispenser (not shown) may move the wrapping material vertically (e.g., up and down) as the turntable 35 rotates to apply wrapping material 34 around a portion of the stacking frame 20, the rolled rugs 5 and a portion of the slip sheet 12. In other embodiments, the wrapping material 34 may be applied manually without a turntable.

In various embodiments, during the wrapping process, portions of the stacking frame posts 22A-D are wrapped along with the rolled rugs 5 as illustrated in FIG. 5. The material wrapped around the stacking frame 20, rolled rugs 5 and slip sheet 12 may be an elastic, thin plastic film (e.g., stretch wrap), a substantially inelastic film, paper, fabric, or other type of wrapping material.

In one embodiment, when the wrapping material 34 is applied, the back wall 18 is engaged by the wrapping material 34 but the flap 14 of the slip sheet 12 is not engaged by the wrapping material 34. In other embodiments, the flap 14 may be engaged by the wrapping material 34.

Undocking Station 40

After applying the wrapping material 34, the wrapped stacking frame 20, rolled rugs 5 and slip sheet 12 are moved to an undocking station 40. The undocking station 40 allows for the wrapped rolled rugs 5 and slip sheet 12 to be removed from the stacking frame 20. The undocking station 40 includes two rails 42 disposed on a supporting surface. The rails 42 are configured to engage the support blocks 26 on the stacking frame. These rails 42 restrict movement of the stacking frame 20 while the rolled rugs 5, slip sheet 12, and wrapping material are lifted off of the stacking frame 20 to create a unitized bundle 10.

FIG. 5 illustrates an undocking station 40 with a stacking frame 20 position thereon according to an embodiment of the present invention. As illustrated, the undocking station includes two rails 42 having a “C” shaped cross-section. The rails 42 are substantially parallel, spaced apart and configured to slideably engage the support blocks 26 secured to the posts 22A-D of the stacking frame 20. In use, the stacking frame 20 is slid into the undocking station 40 such that the support blocks are disposed in the channels created by the rails 42.

In various embodiments, the stacked rolled rugs 5, slip sheet 12, and wrapping material 34 may be removed from the stacking frame 20 using a standard lift truck with a slip sheet fork attachment. The lift truck operator raises the extended portion of the rug bundle proximate the flap 14 and slides the slip sheet attachment base between the slip sheet 12 and the platform 24. Once the slip sheet attachment base is under the stacked rolled rugs, the stacked rolled rugs 5, slip sheet 12, and wrapping material 34 are lifted. As noted above, the undocking station 40 limits the movement of the stacking frame 20 though engagement of the support blocks 26 on each post 22A-D. As a result, the stacked rolled rugs 5, slip sheet 12 and wrapping material 34 are lifted off of the stacking frame 20. Once the wrapping material clears the top of the frame posts 22A-D, the wrapping material may tighten naturally against the rolled rugs and the slip sheet to further secure the rolled rugs together. An example of the resulting unitized rug bundle is illustrated in FIG. 1.

Many modifications and other embodiments of the inventions set forth herein will come to mind to one skilled in the art to which these inventions pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the inventions are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. 

1. A bundle of elongate items comprising: a slip sheet having a planar base portion and at least one flap extending from the base portion; a plurality of elongate items disposed in a plurality of rows atop the slip sheet, wherein a first row is disposed adjacent to the base portion with a longitudinal axis of the elongate items substantially parallel with the plane formed by the base portion; and a wrapping material disposed around the plurality of rows wherein the wrapping material engages both ends of the elongate items and at least a portion of the slip sheet.
 2. The bundle of claim 1, wherein the flap is disposed between a portion of the wrapping material and at least one of the elongate items.
 3. The bundle of claim 1, wherein the base portion is substantially rectangular with the flap extending from one side of the base portion and the slip sheet further comprising a back wall portion extending substantially perpendicularly from an edge of the base portion opposite the flap and two side walls extending perpendicularly from edges adjacent the flap, wherein the two side walls are attached to the back wall.
 4. The bundle of claim 3, wherein the wrapping material engages at least a portion of the back and two side walls but does not engage the flap.
 5. The bundle of claim 1, wherein the flap that extends beyond the elongate length of the elongate items.
 6. The bundle of claim 1, wherein the slip sheet is constructed from cardboard, plastic or metal.
 7. The bundle of claim 1, wherein the elongate items are rolls of textile material.
 8. The bundle of claim 7, wherein the plurality of items is greater than
 50. 9. The bundle of claim 1, wherein the wrapping material is an elastic film.
 10. The bundle of claim 1, wherein the wrapping material is an inelastic film, a fabric or paper.
 11. A bundling system for packaging a plurality of elongate items comprising: a stacking frame configured to align the elongate items, wherein the stacking frame comprises: a substantially planar platform; a plurality of posts attached to the platform, wherein the posts position the platform at a position spaced apart from a supporting surface; and a plurality of support blocks attached to the frame; and an undocking station comprising a plurality of rails configured to slideably engage the support blocks to restrict movement of the stacking frame in a direction substantially perpendicular to the platform.
 12. The bundling system of claim 11, wherein the support blocks are attached to respective posts.
 13. The bundling system of claim 11 further comprising a bar attached to the platform proximate one edge wherein the bar is configured to cooperate with the platform to align items on an inclined relative to the support surface when placed thereon.
 14. The bundling system of claim 11, wherein the platform is inclined relative to the support surface.
 15. The bundling system of claim 11 further comprising a wrapping station configured to apply a wrapping material around the plurality of elongate items disposed in the stacking frame and a portion of the posts.
 16. A method of bundling a plurality of elongate items comprising the steps of: stacking a plurality of elongate items into a plurality of rows atop a slip sheet; and applying wrapping material around the stack of elongate items wherein the wrapping material is engages the ends of the plurality of elongate items and at least a portion of the slip sheet.
 17. The method of claim 16 further comprising the steps of: placing the slip sheet onto a frame between a plurality of posts, wherein the posts are configured to provide lateral support for the elongate items; and the step of applying wrapping material comprises applying the wrapping material around the elongate items and a portion of the plurality of posts.
 18. The method of claim 17 further comprising the steps of: engaging at least one of the posts and removing the stack of elongate items and wrapping material from the frame after applying the wrapping material. 